High Impact and Load Bearing Building Panel

ABSTRACT

A high impact and load bearing building panel includes a first magnesium oxide board, a phenolic resin sheet, an expanded polystyrene layer, and a second magnesium oxide board. The phenolic resin sheet is laminated with the expanded polystyrene layer, and the first magnesium oxide board is laminated with the phenolic resin sheet opposite of the expanded polystyrene layer. The second magnesium oxide board is laminated with the expanded polystyrene layer opposite of the phenolic resin sheet. The high impact and load bearing building panel is used for building construction to construct exterior walls, interior walls, roofs, floors, and foundation systems.

This application is a continuation of U.S. patent application Ser. No.14/179,445 filed on Feb. 12, 2014 which claims the benefit of the U.S.Provisional Patent application No. 61/763,617 filed on Feb. 12, 2013,the U.S. Provisional Patent application No. 61/773,475 filed on Mar. 6,2013, and the U.S. Provisional Patent application No. 61/773,489 filedon Mar. 6, 2013. This application is further a continuation in part ofU.S. patent application Ser. No. 14/630,193 filed Feb. 24, 2015 whichclaims the benefit of U.S. Provisional Patent Application No. 61/943,578filed Feb. 24, 2014.

FIELD OF THE INVENTION

The present invention relates generally to a structural insulated panel.More specifically, the present invention is a high impact and loadbearing structural insulated building panel that is used forconstructing interior walls, exterior walls, floors, and roofs of abuilding structure.

BACKGROUND OF THE INVENTION

Structural insulated panels are composite building material of aninsulating layer of rigid polymer foam sandwiched between two layers ofstructural board. These structural boards can consist of material suchas sheet metal, plywood, particle board, etc while the insulating layerof rigid polymer foam is commonly expanded polystyrene foam, extrudedpolystyrene foam, polyisocyanurate foam, or polyurethane foam. Thestructural insulated panels can be used within many differentconstruction applications, such as exterior walls, interior walls,roofs, floors, and foundation systems since the structural insulatedpanels combine the functionality of the conventional buildingcomponents, such as studs, joists, insulation, vapor barrier, and airbarrier. The main drawback of the structural insulated panels is thatthe conventional structural boards used within the structural insulatedpanels creep and deformed overtime due to load bearings andenvironmental conditions, resulting structural failure within theoverall building.

It is therefore an object of the present invention to provide a loadbearing and high impact insulating building panel that utilizesmagnesium oxide boards bonded to a high density expanded polystyrenefoam core. Due to the components and their configurations, the presentinvention provides an improved structural insulated panel that hassuperior impact and fire resistance compared to any other conventionalstructural insulated panel.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view of the present invention.

FIG. 2 is a top view of the present invention, showing the first andsecond edges.

FIG. 3 is a side view of the present invention, showing the first edge,second edge, first flat surface, and the second flat surface.

FIG. 4 is a top view of the alternative embodiment of the presentinvention, showing the connecting seal section and the spline-receivinggrooves.

DETAIL DESCRIPTIONS OF THE INVENTION

All illustrations of the drawings are for the purpose of describingselected versions of the present invention and are not intended to limitthe scope of the present invention.

The present invention is a high impact and load bearing building panel 1that replaces the conventional structural insulated panel in thebuilding constructions. The present invention is used for constructingthe exterior walls, interior walls, roofs, floors, and foundationsystems of a building structure. The present invention comprises a firstmagnesium oxide board 11, a phenolic resin sheet 12, an expandedpolystyrene layer 13, and a second magnesium oxide board 14.

In reference to FIG. 1-FIG. 3, the phenolic resin sheet 12 is adjacentlylaminated with the expanded polystyrene layer 13 as the phenolic resinsheet 12 improves the fire resistance within the present invention whileproviding superior impact absorbance to the present invention. Thephenolic resin sheet 12 is a lightweight and chemical resistancematerial, wherein those materialistic properties of the phenolic resinsheet 12 improve the overall functionality of the present invention. Theexpanded polystyrene layer 13 is a thermoplastic, closed-cell,lightweight, and rigid-foam material, where the expanded polystyrenelayer 13 provides low thermal conductivity, high compressive strength,and shock absorbing properties to the present invention.

In reference to FIG. 1-FIG. 3, the first magnesium oxide board 11 andthe second magnesium oxide board 14 function as the exterior panels ofthe present invention. More specifically, the first magnesium oxideboard 11 is adjacently laminated to the phenolic resin sheet 12 in suchway that the first magnesium oxide board 11 is oppositely positionedfrom the expanded polystyrene layer 13. The second magnesium oxide board14 is adjacently laminated to the expanded polystyrene layer 13, wherethe second magnesium oxide board 14 is oppositely positioned from thephenolic resin sheet 12. The first magnesium oxide board 11 and thesecond magnesium oxide board 14 provide high strength, fire resistance,mold and mildew control, and sound control functionality to the presentinvention. In reference to general structural construction, the firstmagnesium oxide board 11 is generally considered as the exterior side ofthe structural building while the second magnesium oxide board 14 isgenerally considered as the interior side of the structural building.

Since the first magnesium oxide board 11 and the phenolic resin sheet 12are laminated to each other, the phenolic resin sheet 12 converts thebrittleness of the first magnesium oxide board 11 into high impact panelso that the present invention is able to withstand high impact forcesand high stress forces. In other words, the first magnesium oxide board11 and the phenolic resin sheet 12 form a non-brittle outer layer withinthe present invention. The phenolic resin sheet 12 also acts as abacking for the present invention, where the phenolic resin sheet 12achieve increased screw pull out strengths within the present invention.

Even though the preferred embodiment of the present invention useslaminating connection method, the present invention can utilize any typeof connection methods or any type adhesive materials, such as highpressure bonding, mechanical fasteners, and adhesive, to laminate thefirst magnesium oxide board 11, the phenolic resin sheet 12, theexpanded polystyrene layer 13, and the second magnesium oxide board 14together. Once the first magnesium oxide board 11, the phenolic resinsheet 12, the expanded polystyrene layer 13, and the second magnesiumoxide board 14 are securely laminated to each other, the first magnesiumoxide board 11, the phenolic resin sheet 12, the expanded polystyrenelayer 13, and the second magnesium oxide board 14 function as a singlerigid panel.

In reference to FIG. 3, the first magnesium oxide board 11, the phenolicresin sheet 12, the expanded polystyrene layer 13, and the secondmagnesium oxide board 14 each comprise a first edge 15 and a second edge16. More specifically, the first edge 15 of the first magnesium oxideboard 11, the phenolic resin sheet 12, the expanded polystyrene layer13, and the second magnesium oxide board 14 are oppositely positionedfrom the second edge 16 of the first magnesium oxide board 11, thephenolic resin sheet 12, the expanded polystyrene layer 13, and thesecond magnesium oxide board 14. The first edge 15 of the firstmagnesium oxide board 11, the phenolic resin sheet 12, the expandedpolystyrene layer 13, and the second magnesium oxide board 14 arecoincidently positioned with each other so that the all of the firstedges 15 are able to form a first flat surface 17 within the presentinvention. The first flat surface 17 is perpendicularly positioned withthe first magnesium oxide board 11, the phenolic resin sheet 12, theexpanded polystyrene layer 13, and the second magnesium oxide board 14.

As a result, the first flat surface 17 extends from the first magnesiumoxide board 11 to the second magnesium oxide board 14 and vice versa.Similarly, the second edge 16 of the first magnesium oxide board 11, thephenolic resin sheet 12, the expanded polystyrene layer 13, and thesecond magnesium oxide board 14 are coincidently positioned with eachother so that the all of the second edges 16 are able to form a secondflat surface 18 within the present invention. The second flat surface 18is perpendicularly positioned with the first magnesium oxide board 11,the phenolic resin sheet 12, the expanded polystyrene layer 13, and thesecond magnesium oxide board 14. As a result, the second flat surface 18extends from the first magnesium oxide board 11 to the second magnesiumoxide board 14 and vice versa. Additionally, the first flat surface 17and the second flat surface 18 are oppositely positioned of each otheralong the first magnesium oxide board 11, the phenolic resin sheet 12,the expanded polystyrene layer 13, and the second magnesium oxide board14.

In an alternative embodiment of the present invention that is show inFIG. 4, the first edge 15 of the first magnesium oxide board 11, thephenolic resin sheet 12, the expanded polystyrene layer 13, and thesecond magnesium oxide board 14 are coincidently positioned with eachother so that the all of the first edges 15 are able to form the firstflat surface 17. However, the second edge 16 of the first magnesiumoxide board 11, the expanded polystyrene layer 13, and the secondmagnesium oxide board 14 are coincidently positioned with each other,while, the second edge 16 of the phenolic resin sheet 12 is extendedfrom the second edge 16 of the first magnesium oxide board 11, theexpanded polystyrene layer 13, and the second magnesium oxide board 14.As a result of the offsetting phenolic resin sheet 12, a connecting sealsection 19 can be formed within the present invention.

In another alternative embodiment of the present invention, the presentinvention comprises a plurality of spline-receiving groove 20 thattraverses into the expanded polystyrene layer as each spline-receivinggroove 20 is positioned at each corner of the expanded polystyrenelayer. More specifically, the spline-receiving groove 20 comprises afirst spline-receiving groove, a second spline-receiving groove, a thirdspline-receiving groove, and a fourth spline-receiving groove. The firstspline-receiving groove, the second spline-receiving groove, the thirdspline-receiving groove, and the fourth spline-receiving groove areadjacently positioned with the first edge 15 and the second edge 16 ofthe present invention. More specifically, the first spline-receivinggroove, the second spline-receiving groove, the third spline-receivinggroove, and the fourth spline-receiving groove are traversed into theexpanded polystyrene layer 13. The first spline-receiving groove and thesecond spline-receiving groove are adjacently positioned with the firstmagnesium oxide board 11, where the first spline-receiving groove andthe second spline-receiving groove are oppositely positioned from eachother and positioned parallel to each other. The third spline-receivinggroove and the fourth spline-receiving groove are adjacently positionedwith the second magnesium oxide board 14, where the thirdspline-receiving groove and the fourth spline-receiving groove areoppositely positioned from each other and positioned parallel to eachother. Additionally, the first spline-receiving groove and the thirdspline-receiving groove are coincidently positioned with each otheradjacent to the first edge 15, and the second spline-receiving grooveand the fourth spline-receiving groove are coincidently positioned witheach other adjacent to the second edge 16.

The attachment between the plurality of high impact and load bearingbuilding panels 1 is explained in relation to an arbitrary high impactand load bearing building panel (HILBBP) and a subsequence high impactand load bearing building panel (HILBBP). In order to efficiently attachthe arbitrary HILBBP and the subsequence HILBBP together, the presentinvention utilizes the connecting seal section 19, a first connectingspline, and a second connecting spline. The first connecting spline andthe second connecting spline each comprises a magnesium oxide boardsection and a phenolic resin sheet section as the magnesium oxide boardsection and the phenolic resin sheet section are adjacently laminated toeach other. When the arbitrary HILBBP and the subsequence HILBBP areadjacently placed next to each other, the connecting seal section 19 ofthe arbitrary HILBBP is traversed into the first spline-receiving grooveof the subsequence HILBBP. The connecting seal section 19 of thearbitrary HILBBP then overlaps the first edge 15 of the phenolic resinsheet 12 for the subsequence HILBBP in such way that the connecting sealsection 19 and the first edge 15 of the of the phenolic resin sheet 12form a watertight seal. The connecting seal section 19 of the arbitraryHILBBP forms a barrier against water and moisture intrusion into thebuilding envelope system. Once the arbitrary HILBBP and the subsequenceHILBBP are positioned together, the second spline-receiving groove andthe fourth spline-receiving groove of the arbitrary HILBBP arerespectively positioned with the first spline-receiving groove and thethird spline-receiving groove of the subsequence HILBBP. The firstconnecting spline traverses into the first spline-receiving groove ofthe subsequence HILBBP and the second spline-receiving groove of thearbitrary HILBBP in such way that the phenolic resin sheet section ofthe first connecting spline is adjacently positioned with the expandedpolystyrene layers 13, and the magnesium oxide board section of thefirst connecting spline is adjacently positioned with the connectingseal section 19. The second connecting spline traverses into the thirdspline-receiving groove of the subsequence HILBBP and the fourthspline-receiving groove of the arbitrary HILBBP in such way that thephenolic resin sheet section of the second connecting spline isadjacently positioned with the expanded polystyrene layers 13, and themagnesium oxide board section of the second connecting spline isadjacently positioned with the second magnesium oxide boards 14. Aplurality of fasteners is used to attach the arbitrary HILBBP and thesubsequence HILBBP during the multiple attachment of the presentinvention. More specifically, the plurality of fasteners is externallytraversed through the first magnesium oxide boards 11 and the phenolicresin sheet 12 and into the first connecting spline so that thearbitrary HILBBP and the subsequence HILBBP can be attached to eachother from the exterior side of the structural building. Similarly, theplurality of fasteners is externally traversed through the secondmagnesium oxide boards 14 and into the second connecting spline so thatthe arbitrary HILBBP and the subsequence HILBBP can be attached to eachother from the interior side of the structural building.

Although the invention has been explained in relation to its preferredembodiment, it is to be understood that many other possiblemodifications and variations can be made without departing from thespirit and scope of the invention as hereinafter claimed.

What is claimed is:
 1. A high impact and load bearing building panelcomprises: a first magnesium oxide board; a phenolic resin sheet,wherein the phenolic resin sheet provide fire resistance and impactabsorbance; an expanded polystyrene layer; a second magnesium oxideboard; the phenolic resin sheet being adjacently laminated with theexpanded polystyrene layer; the first magnesium oxide board beingadjacently laminated to the phenolic resin sheet opposite from theexpanded polystyrene layer; the second magnesium oxide board beingadjacently laminated to the expanded polystyrene layer opposite from thephenolic resin sheet; and the first magnesium oxide board and thephenolic resin sheet form a non-brittle outer layer.
 2. The high impactand load bearing building panel as claimed in claim 1 comprises: thefirst magnesium oxide board, the phenolic resin sheet, the expandedpolystyrene layer, and the second magnesium oxide board each comprise afirst edge and a second edge; the first edge of the first magnesiumoxide board, the phenolic resin sheet, the expanded polystyrene layer,and the second magnesium oxide board being coincidently positioned witheach other to form a first flat surface; the second edge of the firstmagnesium oxide board, the phenolic resin sheet, the expandedpolystyrene layer, and the second magnesium oxide board beingcoincidently positioned with each other to form a second flat surface;and the first flat surface and the second flat surface being oppositelypositioned of each other.
 3. The high impact and load bearing buildingpanel as claimed in claim 1 comprises: the first magnesium oxide board,the phenolic resin sheet, the expanded polystyrene layer, and the secondmagnesium oxide board each comprise a first edge and a second edge; thefirst edge of the first magnesium oxide board, the phenolic resin sheet,the expanded polystyrene layer, and the second magnesium oxide boardbeing coincidently positioned with each other to form a first flatsurface; the second edge of the first magnesium oxide board, theexpanded polystyrene layer, and the second magnesium oxide board beingcoincidently positioned with each other; and the second edge of thephenolic resin sheet being extended from the second edge of the firstmagnesium oxide board, the expanded polystyrene layer, and the secondmagnesium oxide board to form a connecting seal section.
 4. The highimpact and load bearing building panel as claimed in claim 1 comprises:a plurality of spline-receiving grooves traversing into the expandedpolystyrene layer, wherein each spline-receiving groove is positioned ateach corner of the expanded polystyrene layer.